Star EV Lithium 48V Classic/Sport Installation Manual

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Star EV Lithium 48V Classic/Sport

Installation Guide

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Page 1 Star EV Lithium 48V Classic/Sport Installation Guide...
Page 2 Contacts to know Star EV Technical Support 864-553-7147 www.starev.com www.starev.com...
Page 3: Table Of Contents
Table of Contents Tools Needed ....................4 Kit Contents .....................5 Battery Removal Process ................6 Battery Compartment Preparation..............8 Battery Installation ..................10 Removing Your SLA Charger ...............15 Installing Your New Charger-On-board ............16 Installing Your New Charger-Off-board ............19 Basic Operation....................21 General Troubleshooting ................22 IMPORTANT NOTE: Your Lithium battery will not arrive fully charged! You must fully charge your Lithium unit BEFORE operating! This Lithium kit is intended for OEM motor/contoller applications! www.starev.com...
Page 4: Tools Needed
Tools Needed For battery removal, you will need to have a ratchet, with an extension, a 14mm deep socket, and a 13mm deep socket. You may also want to have a battery lifting strap, to help lift the lead acid batteries out of the vehicle. You will need wire cutters for cutting the zip ties that hold the old charger wiring to the frame rails.
Page 5: Kit Contents
Kit Contents The installation of this kit must be performed by a Star dealer, in order to retain your Star vehicle warranty. 2CH917 and 2CH918 Receptacle Adapter Plate and Seal 2RC080 Receptacle (top left) These parts in red are 2CH913 Remote LED (top right)
Page 6: Battery Removal Process
Battery Removal Process To make it easier to access and remove the batteries, it will be a huge help to remove the seat cushion. To remove, raise the seat upward, and slide the hinges apart. You will see that the hinges are able to slide apart, when the seat cushion is in the upright position.
Page 7 With the compartment now cleared out, you can install the Star EV lithium battery mounting plate. This is the 2BT291 Mounting Plate. You will need the 4-M8x1.25x65mm button head bolts, 4-M8x1.25 nylock nuts, and 4-M8 flat washers to secure this plate into the car, from the hardware kit 2HD050-Hardware Kit #3 (2HD002).
Page 8: Battery Compartment Preparation
Battery Compartment Preparation When your battery tray tub has been removed, tabs cut off and painted, this is what the battery compartment will look like. You will move all wiring so that it is outside of the horizontal lip of the angle iron that makes up the frame.
Page 9 You are ready to install the washers and nylock nuts onto the mounting plate bolts. Use a wrench and 13mm socket to tighten all 4 of the bolts and nuts. Your battery mounting plate is now installed, and ready for the battery installation. www.starev.com...
Page 10: Battery Installation
Battery Installation The battery shown here, is the 105Ah lithium unit, but the 80Ah and 210Ah units are almost the same, except for the orientation of the mounting tabs. In the photo below, you will see the 105Ah battery mounting holes circled in red, and the 210Ah shown in green.
Page 11 At this point, you will have the battery mounting plate bolted in, along with the lithium battery. You will need to connect the main battery cables to the main battery terminals on the side of the battery. Be sure the battery power switch is off, for the 80Ah or 105Ah batteries.
Page 12 Remove the retaining nut from the back of the dash Coulometer. This will allow the old meter to be removed, leaving an opening for the new meter on the end of the 2MT223 cable that was just run from the battery compartment. Install the new meter into the dash. It should snap into the opening.
Page 13 At this point, you will connect the chrome-plated screw lock connector to the KEY/CAN port on the side of the battery. You can now press the battery power button, for 80Ah and 105Ah, and turn the key and the battery should turn on.
Page 14 Star Lithium Classic/ Sport Conversion Kit Connector Wiring Diagram OEM Off-board charger shown. If OEM On-board charger, then cart will Connections have receptacle and AC Summit II Charger charger cable already. Charger Cable 2CR020 DB9 Connector (Not Used) KEY/CAN Lithium Battery...
Page 15: Removing Your Sla Charger
Removing Your SLA Charger You will need to remove the 650W charger, for the lead acid batteries in order to replace it with the new 1050W charger for the lithium application. For the 4 or 4+2 cart, you will find the lead acid charger mounted underneath the front seat of the vehicle.
Page 16: Installing Your New Charger-On-Board
Replacing Your Charger | On board Now find the cord package marked 2CR020. This cord will connect the DC side of the charger to the battery pack. You will use a Phillips screwdriver to remove the black plastic cover from the finned side of the charger.
Page 17 Locate your charger brackets and use the M6x1.0x25mm bolts, 8-M6 flat washers, and 4-nylock nuts to attach the charger brackets to the back of the charger, loosely at this time. Next, you will need to use a drill and a 3/8” drill bit to place 2 holes in the driver side tray area of the battery compartment.
Page 18 Now that you have the charger installed you will connect the 3 prong plug from the charger receptacle to the charger. You are now able to connect the charger cord, with the blue twist- lock connector to the charger port of the battery.
Page 19: Installing Your New Charger-Off-Board
Installing Your Charger | Off board If your vehicle originally came with an off-board charger configuration, we will now convert it to on-board. Locate your charger receptacle, PN: 2RC080. You will also need to locate your M4x0.7x25mm button head screws, M4 washers, M4 lock washers, and M4x0.7 nuts.
Page 20 Using the M6x1x25mm button head screws, M6 washers, M6 lockwasher and M6x1 nuts you will attach the receptacle/plate/gasket assembly into the vehicle body. Tighten the bolts to hold the assembly into the cart. Now we will turn our attention to the charger receptacle wiring.
Page 21: Basic Operation
Basic Operation Lithium Battery Pack: 1. Battery must be fully charged before use, in order to properly calibrate the meter. 2. The lithium battery must have continuity through the key switch circuit in order to power on. The dashboard pushbutton acts as this key switch input. Turn on the battery power switch, then the dash pushbutton.
Page 22: General Troubleshooting
Here are some general troubleshooting questions: battery before operating!) Q: What if there is something missing from my Star lithium battery kit? A: Call the Star accessory parts department, at 864-553-7969. Q: What if my battery won’t turn on? A: Verify that your battery power switch is pushed in, along with your dashboard pushbutton switch.